Johnson Controls YORK YCAL0041EC Owner's manual

YCAL0041EC - YCAL0071EC
AIR-COOLED
SCROLL CHILLERS
STYLE D
WITH IPU II & I/O BOARDS
(60 Hz)
35-60 TON
INSTALLATION, OPERATION, MAINTENANCE
AIR-COOLED LIQUID CHILLERS
HERMETIC SCROLL
Supersedes 150.66-NM1 (1005) Form 150.66-NM1 (708)
LD10950
R-22
035-20895-000

JOHNSON CONTROLS
2
FORM 150.66-NM1 (708)
This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
oils, materials under pressure, rotating components,
and both high and low voltage. Each of these items
has the potential, if misused or handled improperly, to
cause bodily injury or death. It is the obligation and
responsibility of operating/service personnel to identify
and recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure to
comply with any of these requirements could result in
serious damage to the equipment and the property in
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
This document is intended for use by owner-authorized
operating/service personnel. It is expected that this
individual possesses independent training that will
enable them to perform their assigned tasks properly
and safely. It is essential that, prior to performing any
task on this equipment, this individual shall have read
and understood this document and any referenced
materials. This individual shall also be familiar with and
comply with all applicable governmental standards and
regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:
CAUTION identifies a hazard which
could lead to damage to the machine,
damage to other equipment and/or
environmental pollution. Usually an
instruction will be given, together with
a brief explanation.
NOTE is used to highlight additional
information which may be helpful to
you.
DANGER indicates an imminently
hazardous situation which, if not
avoided, will result in death or serious
injury.
WARNING indicates a potentially
hazardous situation which, if not
avoided, could result in death or se-
rious injury.
External wiring, unless specified as an optional connection in the manufacturer’s product
line, is NOT to be connected inside the micro panel cabinet. Devices such as relays, switches,
transducers and controls may NOT be installed inside the panel. NO external wiring is al-
lowed to be run through the micro panel. All wiring must be in accordance with YORK’s
published specifications and must be performed ONLY by qualified YORK personnel. YORK
will not be responsible for damages/problems resulting from improper connections to the
controls or application of improper control signals. Failure to follow this will void the
manufacturer’s warranty and cause serious damage to property or injury to persons.

FORM 150.66-NM1 (708)
3
JOHNSON CONTROLS
CHANGEABILITY OF THIS DOCUMENT
In complying with YORK’s policy for continuous product improvement, the information contained in this document
is subject to change without notice. While YORK makes no commitment to update or provide current information
automatically to the manual owner, that information, if applicable, can be obtained by contacting the nearest YORK
Engineered Systems Service office.
It is the responsibility of operating/service personnel to verify the applicability of these documents to the equipment in
question. If there is any question in the mind of operating/service personnel as to the applicability of these documents,
then prior to working on the equipment, they should verify with the owner whether the equipment has been modified
and if current literature is available.

JOHNSON CONTROLS
4
FORM 150.66-NM1 (708)
TABLE OF CONTENTS
GENERAL SAFETY GUIDELINES......................................................................................................2
TABLE OF CONTENTS .......................................................................................................................4
LIST OF FIGURES...............................................................................................................................9
LIST OF TABLES...............................................................................................................................10
SECTION 1 - GENERAL CHILLER INFORMATION & SAFETY ......................................................13
INTRODUCTION .........................................................................................................................................13
WARRANTY ................................................................................................................................................13
SAFETY.......................................................................................................................................................13
Standards for Safety ...........................................................................................................................13
RESPONSIBILITY FOR SAFETY ...............................................................................................................14
ABOUT THIS MANUAL ..............................................................................................................................14
MISUSE OF EQUIPMENT...........................................................................................................................14
Suitability for Application ...................................................................................................................14
Structural Support...............................................................................................................................14
Mechanical Strength ..........................................................................................................................15
General Access....................................................................................................................................15
Pressure Systems ...............................................................................................................................15
Electrical...............................................................................................................................................15
Rotating Parts ......................................................................................................................................15
Sharp Edges.........................................................................................................................................15
Refrigerants and Oils ..........................................................................................................................15
High Temperature and Pressure Cleaning ........................................................................................15
Emergency Shutdown.........................................................................................................................15
SECTION 2 - PRODUCT DESCRIPTION..........................................................................................16
INTRODUCTION .........................................................................................................................................16
GENERAL SYSTEM DESCRIPTION ..........................................................................................................16
Compressors .......................................................................................................................................16
Cooler ...................................................................................................................................................16
Condenser............................................................................................................................................17
Millennium Control Center..................................................................................................................17
Power Panel .........................................................................................................................................18
ACCESSORIES AND OPTIONS .................................................................................................................19
Power Options: ....................................................................................................................................19
Control Options: ..................................................................................................................................19
Compressor, Piping, Evaporator Options .........................................................................................20
Condenser and Cabinet Options........................................................................................................20
Sound Reduction Options ..................................................................................................................21
UNIT COMPONENTS..................................................................................................................................22
CONTROL / POWER PANEL COMPONENTS ...........................................................................................23
PRODUCT IDENTIFICATION NUMBER (PIN)............................................................................................24
UNIT NOMENCLATURE .............................................................................................................................24
BASIC UNIT NOMENCLATURE .................................................................................................................24
REFRIGERANT FLOW DIAGRAM .............................................................................................................29
SECTION 3 - HANDLING AND STORAGE.......................................................................................30
DELIVERY AND STORAGE........................................................................................................................30
INSPECTION ...............................................................................................................................................30
MOVING THE CHILLER..............................................................................................................................30
Lifting Weights.....................................................................................................................................30
UNIT RIGGING ............................................................................................................................................31

FORM 150.66-NM1 (708)
5
JOHNSON CONTROLS
TABLE OF CONTENTS (CONT’D)
SECTION 4 - INSTALLATION ...........................................................................................................32
INSTALLATION CHECKLIST......................................................................................................................32
HANDLING ..................................................................................................................................................32
INSPECTION ...............................................................................................................................................32
LOCATION AND CLEARANCES................................................................................................................32
Foundation ...........................................................................................................................................33
Ground Level Locations .....................................................................................................................33
Rooftop Locations...............................................................................................................................33
Noise Sensitive Locations ..................................................................................................................33
SPRING ISOLATORS (OPTIONAL)............................................................................................................33
COMPRESSOR MOUNTING ......................................................................................................................33
REMOTE COOLER OPTION ......................................................................................................................33
CHILLED LIQUID PIPING ...........................................................................................................................33
DUCT WORK CONNECTION ....................................................................................................................34
WIRING........................................................................................................................................................34
Evaporator Pump Start Contacts .......................................................................................................35
System Run Contacts .........................................................................................................................35
Alarm Status Contacts ........................................................................................................................35
Remote Start/Stop Contacts...............................................................................................................35
Remote Emergency Cutoff .................................................................................................................35
PWM Input ............................................................................................................................................35
Load Limit Input...................................................................................................................................35
Flow Switch Input ................................................................................................................................35
COMPRESSOR HEATERS .........................................................................................................................35
SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED DISCONNECT
SWITCH OR CIRCUIT BREAKER (0041 - 0071) .......................................................................................36
SINGLE-POINT SUPPLY CONNECTION ...................................................................................................36
CONTROL WIRING.....................................................................................................................................37
SECTION 5 - COMMISSIONING .......................................................................................................38
PREPARATION – POWER OFF..................................................................................................................38
Inspection ...........................................................................................................................................38
Refrigerant Charge ..............................................................................................................................38
Service and Oil Line Valves ................................................................................................................38
Compressor Oil....................................................................................................................................38
Fans .....................................................................................................................................................38
Isolation / Protection ...........................................................................................................................38
Control Panel .......................................................................................................................................38
Power Connections .............................................................................................................................38
Grounding ............................................................................................................................................39
Supply Voltage.....................................................................................................................................39
PREPARATION – POWER ON ...................................................................................................................39
Switch Settings....................................................................................................................................39
Compressor Heaters ...........................................................................................................................39
Water System .......................................................................................................................................39
Flow Switch..........................................................................................................................................39
Temperature Sensor(s) .......................................................................................................................39
EQUIPMENT STARTUP CHECKLIST ........................................................................................................40
Checking the System Prior To Initial Start (No Power) ....................................................................40
Compressor Heaters (Power ON – 24 Hours Prior To Start) ...........................................................40
Panel Checks (Power ON – Both Unit Switches OFF)....................................................................40

JOHNSON CONTROLS
6
FORM 150.66-NM1 (708)
TABLE OF CONTENTS (CONT’D)
SETPOINTS ENTRY LIST...........................................................................................................................41
CHECKING SUPERHEAT AND SUBCOOLING.........................................................................................42
LEAK CHECKING .......................................................................................................................................42
UNIT OPERATING SEQUENCE .................................................................................................................43
SECTION 6 - TECHNICAL DATA ......................................................................................................44
OPERATIONAL LIMITATIONS (ENGLISH) ................................................................................................44
Temperatures and Flows ....................................................................................................................44
Voltage Limitations..............................................................................................................................44
Ethylene Glycol Correction Factors ..................................................................................................45
OPERATIONAL LIMITATIONS (SI).............................................................................................................46
Temperatures and Flows ....................................................................................................................46
Voltage Limitations..............................................................................................................................46
Ethylene Glycol Correction Factors ..................................................................................................47
PHYSICAL DATA (ENGLISH) .....................................................................................................................48
SOUND DATA (ENGLISH) ..........................................................................................................................50
ELCTRICAL DATA (ENGLISH) ...................................................................................................................52
ELECTRICAL NOTES AND LEGEND ........................................................................................................55
WIRING DIAGRAMS ...................................................................................................................................56
CONNECTION DIAGRAMS ........................................................................................................................63
DIMENSIONS - (ENGLISH).........................................................................................................................66
DIMENSIONS - (SI) .....................................................................................................................................80
TECHNICAL DATA - CLEARANCES..........................................................................................................94
ISOLATORS ................................................................................................................................................95
SECTION 7 - UNIT CONTROLS......................................................................................................101
INTRODUCTION .......................................................................................................................................101
MICROPROCESSOR BOARD..................................................................................................................101
UNIT SWITCH ...........................................................................................................................................102
DISPLAY....................................................................................................................................................102
KEYPAD ....................................................................................................................................................102
BATTERY BACK-UP.................................................................................................................................102
TRANSFORMER ......................................................................................................................................102
SINGLE SYSTEM SELECT ANDPROGRAMMING # OF COMPRESSORS ..........................................102
“STATUS” KEY ........................................................................................................................................103
Unit Status..........................................................................................................................................103
General Status Messages .................................................................................................................103
Fault safety Status Messages ..........................................................................................................105
System Safeties............................................................................................................................105
Unit Safeties: ................................................................................................................................107
Unit Warning ......................................................................................................................................107
STATUS KEY MESSAGES QUICK REFERENCE LIST...........................................................................108
DISPLAY/PRINT KEYS .............................................................................................................................109
Oper Data Key....................................................................................................................................109
Operation Data Quick Reference List .............................................................................................. 112
Print Key.............................................................................................................................................113
Operating Data Printout ....................................................................................................................113
History Printout .................................................................................................................................114
History Displays ................................................................................................................................114
Software Version ...............................................................................................................................116

FORM 150.66-NM1 (708)
7
JOHNSON CONTROLS
TABLE OF CONTENTS (CONT’D)
“ENTRY” KEYS......................................................................................................................................... 117
Up and Down Arrow Keys.................................................................................................................117
Enter/Adv Key ....................................................................................................................................117
“SETPOINTS” KEYS ................................................................................................................................118
Cooling Setpoints..............................................................................................................................118
Leaving Chilled Liquid Control ........................................................................................................118
Return Chilled Liquid Control ..........................................................................................................119
Remote Setpoint Control ..................................................................................................................119
Schedule/advance Day Key ..............................................................................................................119
Program Key ......................................................................................................................................121
System Trip Volts .........................................................................................................................122
Unit Trip Volts ...............................................................................................................................123
Program Key Limits and Defaults ....................................................................................................124
Setpoints Quick Reference List .......................................................................................................125
“UNIT” KEYS ...........................................................................................................................................126
Options Key .......................................................................................................................................126
CLOCK ......................................................................................................................................................130
UNIT KEYS PROGRAMMING QUICK REFERENCE LIST ......................................................................131
SECTION 8 - UNIT OPERATION.....................................................................................................132
CAPACITY CONTROL ..............................................................................................................................132
SUCTION PRESSURE LIMIT CONTROLS ..............................................................................................132
DISCHARGE PRESSURE LIMIT CONTROLS .........................................................................................132
LEAVING CHILLED LIQUID CONTROL...................................................................................................132
LEAVING CHILLED LIQUID CONTROLOVERRIDE TO REDUCE CYCLING.........................................133
LEAVING CHILLED LIQUID SYSTEM LEAD/LAG AND COMPRESSOR SEQUENCING .....................133
RETURN CHILLED LIQUID CONTROL....................................................................................................133
RETURN CHILLLED LIQUID SYSTEM LEAD/LAG AND COMPRESSOR SEQUENCING ....................134
ANTI-RECYCLE TIMER ............................................................................................................................135
ANTI-COINCIDENCE TIMER ....................................................................................................................135
EVAPORATOR PUMP CONTROL ............................................................................................................135
EVAPORATOR HEATER CONTROL........................................................................................................135
PUMPDOWN CONTROL ..........................................................................................................................136
CONDENSER FAN CONTROL .................................................................................................................136
LOW AMBIENT FAN CONTROL OPTION................................................................................................138
General ...............................................................................................................................................138
Configuration (Jumpers and Potentiometers) ................................................................................139
Wiring .................................................................................................................................................140
PROGRAMMING.......................................................................................................................................141
LOAD LIMITING ........................................................................................................................................141
COMPRESSOR RUN STATUS .................................................................................................................142
ALARM STATUS .......................................................................................................................................142
EMS-PWM REMOTE TEMPERATURE RESET........................................................................................142
BAS/EMS TEMPERATURE RESET OPTION...........................................................................................143

JOHNSON CONTROLS
8
FORM 150.66-NM1 (708)
TABLE OF CONTENTS (CONT’D)
SECTION 9 - SERVICE AND TROUBLESHOOTING .....................................................................145
CLEARING HISTORY BUFFERS .............................................................................................................145
SERVICE MODE – OUTPUTS ..................................................................................................................145
SERVICE MODE – CHILLER CONFIGURATION.....................................................................................145
SERVICE MODE – INPUTS ......................................................................................................................146
CONTROL INPUTS/OUTPUTS.................................................................................................................147
IPU II & I/O LAYOUT .................................................................................................................................148
CHECKING INPUTS AND OUTPUTS.......................................................................................................149
Digital Inputs......................................................................................................................................149
Analog Inputs – Temperature ...........................................................................................................149
Outside Air Sensor ............................................................................................................................149
Liquid & Refrigerant Sensor Test Points ........................................................................................150
Analog Inputs – Pressure .................................................................................................................151
Digital Outputs...................................................................................................................................152
OPTIONAL PRINTER INSTALLATION.....................................................................................................153
Parts....................................................................................................................................................153
Assembly and Wiring ........................................................................................................................153
Obtaining a Printout ..........................................................................................................................153
TROUBLESHOOTING ..............................................................................................................................154
SECTION 10 - MAINTENANCE.......................................................................................................157
IMPORTANT ..............................................................................................................................................157
COMPRESSORS.......................................................................................................................................157
Oil Level check ..................................................................................................................................157
Oil Analysis ........................................................................................................................................157
CONDENSER FAN MOTORS ...................................................................................................................157
CONDENSER COILS ................................................................................................................................157
OPERATING PARAMETERS ....................................................................................................................157
ON-BOARD BATTERY BACK-UP ............................................................................................................157
PLATE AND FRAME HEAT EXCHANGER (EVAPORATOR) HEATER...................................................157
OVERALL UNIT INSPECTION .................................................................................................................158
ISN CONTROL ..........................................................................................................................................159
Received Data (Control Data) ...........................................................................................................159
Transmitted Data ...............................................................................................................................159
BACNET AND MODBUS DATA COMMUNICATION................................................................................162

FORM 150.66-NM1 (708)
9
JOHNSON CONTROLS
LIST OF FIGURES
FIG. 1 – REFRIGERANT FLOW DIAGRAM......................................................................................29
FIG. 2 – SINGLE-POINT SUPPLY CONNECTION – TERMINAL BLOCK, NON-FUSED
DISCONNECT SWITCH OR CIRCUIT BREAKER (0041 - 0071) .......................................36
FIG. 3 – CONTROL WIRING ............................................................................................................37
FIG. 4 – CONTROL CIRCUIT, DUAL.................................................................................................56
FIG. 5 – CONTROL CIRCUIT, DUAL.................................................................................................58
FIG. 6 – POWER CIRCUIT, DUAL.....................................................................................................60
FIG. 7 – POWER CIRCUIT, DUAL.....................................................................................................61
FIG. 8 – WIRING DETAILS ................................................................................................................62
FIG. 9 – CONNECTION DIAGRAM ...................................................................................................63
FIG. 10 – CONNECTION DIAGRAM .................................................................................................64
FIG. 11 – CONNECTION DIAGRAM MICROBOARD (PARTIAL) ....................................................65
FIG. 12 – UNIT CLEARANCES .........................................................................................................94
FIG. 13 – LEAVING WATER TEMPERATURE CONTROL EXAMPLE...........................................133
FIG. 14 – SETPOINT ADJUST ........................................................................................................133
FIG. 15 – YCAL0041 – YCAL0071 FAN LOCATION (TYPICAL) ...................................................137
FIG. 16 – TYPICAL INVERTER LOCATION ...................................................................................138
FIG. 17 – INVERTER ENCLOSURE................................................................................................138
FIG. 18 – POTENTIOMETER SETTINGS........................................................................................139
FIG. 19 – INVERTER POWER WIRING SCHEMATIC ....................................................................140
FIG. 20 – INVERTER WIRING.........................................................................................................140
FIG. 21 – FIELD AND FACTORY ELECTRICAL CONNECTIONS OPTIONAL REMOTE
TEMPERATURE RESET BOARD ...................................................................................144
FIG. 22 – IPU II & I/O LAYOUT........................................................................................................148
FIG. 23 – MICROBOARD RELAY CONTACT ARCHITECTURE....................................................152
FIG. 24 – PRINTER TO MICROBOARD ELECTRICAL CONNECTIONS ......................................153

JOHNSON CONTROLS
10
FORM 150.66-NM1 (708)
LIST OF TABLES
TABLE 1 – SETPOINTS ENTRY LIST...............................................................................................41
TABLE 2 – TEMPERATURES AND FLOWS.....................................................................................44
TABLE 3 – VOLTAGE LIMITATIONS ................................................................................................44
TABLE 4 – ETHYLENE GLYCOL CORRECTION FACTORS ..............................................................45
TABLE 5 – TEMPERATURES AND FLOWS (SI)..............................................................................46
TABLE 6 – VOLTAGE LIMITATIONS ................................................................................................46
TABLE 7 – ETHYLENE GLYCOL CORRECTION FACTORS ..............................................................47
TABLE 8 – PHYSICAL DATA (ENGLISH) .........................................................................................48
TABLE 9 – SOUND DATA (ENGLISH) ..............................................................................................50
TABLE 10 – ELECTRICAL DATA (ENGLISH) ..................................................................................52
TABLE 11 – MICRO PANEL POWER SUPPLY ................................................................................54
TABLE 12 – VOLTAGE RANGE ........................................................................................................54
TABLE 13 – STATUS KEY MESSAGES QUICK REFERENCE LIST.............................................108
TABLE 14 – OPERATION DATA .....................................................................................................112
TABLE 15 – COOLING SETPOINTS, PROGRAMMABLE LIMITS AND DEFAULTS....................120
TABLE 16 – PROGRAM KEY LIMITS AND DEFAULTS ................................................................124
TABLE 17 – SETPOINTS QUICK REFERENCE LIST....................................................................125
TABLE 18 – UNIT KEYS PROGRAMMING QUICK REFERENCE LIST........................................131
TABLE 19 – COMPRESSOR STAGING FOR RETURN WATER CONTROL.................................134
TABLE 20 – RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS (6 STEPS) ..........135
TABLE 21 – RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS (6 STEPS) ..........136
TABLE 22 – YCAL0041 – YCAL0071 CONDENSER FAN CONTROL USING OUTDOOR
AMBIENT TEMPERATURE AND DISCHARGE PRESSURE (DISCHARGE
PRESSURE CONTROLS WILL NOT FUNCTION AND FAN CONTROL WILL BE
BASED ON AMBIENT TEMPERATURES ONLY, UNLESS THE OPTIONAL
DISCHARGE PRESSURE .........................................................................................137
TABLE 23 – YCAL0041 – YCAL0071 CONDENSER FAN CONTROL USING DISCHARGE
PRESSURE ONLY ......................................................................................................137
TABLE 24 – INVERTER OPTION CONDENSER FAN CONTROL OPERATION...........................141
TABLE 25 – COMPRESSOR OPERATION – LOAD LIMITING......................................................142
TABLE 26 – MICROBOARD DIGITAL INPUTS ..............................................................................147
TABLE 27 – MICROBOARD DIGITAL OUTPUTS ..........................................................................147
TABLE 28 – MICROBOARD ANALOG INPUTS .............................................................................147
TABLE 29 – MICROBOARD ANALOG OUTPUTS .........................................................................147
TABLE 30 – OUTDOOR AIR SENSOR TEMPERATURE/VOLTAGE/ RESISTANCE
CORRELATION ..........................................................................................................149
TABLE 31 – ENTERING/LEAVING CHILLED LIQUID TEMP. SENSOR, COOLER INLET
TEMPERATURE SENSOR, AND SUCTION TEMPERATURE SENSOR:
TEMPERATURE/VOLTAGE CORRELATION ............................................................150
TABLE 32 – TROUBLESHOOTING ................................................................................................154